Apparatus for forming thin wall articles of manufacture from expandable fusible plastic



3,167,811 FACTURE Feb. 2, 1965 R. A. KRAUs ETAL APPARATUS RoR FORMING THIN WALL ARTICLES oF MANU FROM EXPANDABLE FUSIBLE PLASTIC 4 Sheets-Sheet l Filed April 14, 1960 me d @Mama 0 y @fur/l s Hopferj IN VEN TORS.

WMM@ f/A/AA` .Haager .Ke/ws, 7l/WND c): Jip/ws,

rraemsy;

Feb. 2, 1965 R. A. KRAUS ETAL 3,167,811

APPARATUS FOR FORMING THN WALL ARTICLES oF MANUFACTURE FROM EXPANDABLE FUSIBLE PLASTIC v Filed April 14, 1960 4 Sheets-Sheet 2 INVENToR n, Q N B m, finden/A351 Feb. 2, 1965 R. A. KRAUS ETAL 3,167,811

APPARATUS PoP PORMING THIN wALL ARTICLES oF MANUFACTUPE FROM EXPAND/ABLE PUSIBLE PLASTIC Filed April 14, 1960 4 Sheets-Sheet 5 jp f60 15! ,Poseer J4. .KP/10S, E70/HUND C'. .759405,

INVENTOILS` Feb. 2, 1965 R. A. KRAUs ETAL 3,167,811

APPARATUS FOR FORMING THIN wALL ARTICLES oF MANUFACTURE FROM EXPANDABLE FusIBLE PLASTIC Filed April 14, 1960 4 Sheets-Sheet 4 w l JQBERTA .MQ/Ws,

DMz/A/D Cl. .762.24453 1NVENTQR5 BWM/1% turing cups from granular plastic material. f During recent years expandable or foamable plastic APPARATUS FR FRMENG T WALL ARTI- CLES 0F MANUFACTURE FRM EXPANDABLE This invention relates to the manufacture of cups and more particularly to an improved apparatus for manufacmaterials have been developed which have properties peculiarly adapted to the manufacture of containers such as cups and food containers. Such expandable plastic materials are available inthe form. of small beads containing an expanding agent under various trade names such as Pelistan, which is a trademark ofthe Dow Chemical Co., and Dylite, which is a trademark of the Koppers Company, Inc. The most -'commonly available expandable plastics of this type are formed of chemicals such `as polystyrene or the like and are formed as beads containing a foaming or chargingagent such as rnethylchloride, butane, heptane or the like. Normally the plastic vmaterial is supplied as small beads which are impregnated with the foaming agent and are of a size which varies from the manufacture but `is of the order of sixty to seventy-thousandths of an inch in diameter. the beads are confined in a retaining mold and heated they expand and adhere together to forma unicellular rigid material. The desirable characteristics of the material which vmake Vthem particularly adapted to theY manufacture of containers for liquids and foodstuffs includes a low thermoconductivity, low lwater absorption, lo-w densities, a lack of'odor, and the fact that they have no toxicological effects. Thus, for example, cups formed of such .material are particularly desirable for containing hot or cold liquids since the heat insulating properties of the material will retain the. temperature of the liquid contained therein relativelyl constant. In addition, unlike various paper cups formed of paper or other pulp products,

no taste is imparted to the liquid contained. In addition,

the material is sufficiently inexpensive that the cups may be made disposable and manufactured as an item which isintended to be disposed of after one use. The characteristics of the material make it possible to dispose of the'cup by smashing or fracturing with'no danger of cutting or harming the user.

However, in the manufacture of such containers and otherintricate shapes from the foamable polystyrenes, manufacturing diiculties are encountered which are of a nature peculiar to the material itself and prior art apparatus for forming intricate shapes from the material have had various disadvantages for mass production or economical production of intricate Vshapessuch'as cupshaped articles. The apparatus of the present invention is intended to provide an economical method and means for forming shapes of finished unicellular articles of such material. The apparatus of the present invention is particularly adapted to the manufacture of cups for holding liquids and food-stuff and Will accordingly be described throughout the following specification in connection with such use. It is to be understood, however, that the various l the manufacture of many different products. For clarity When saisit Patented Feb. 2, 1965 Fice terial is not easily flowable and if heated ina mold Without even dispersion of the unexpanded material throughout lthe mold a uniform density in the finished article will not be obtained. Among other-reasons for the difculty in flow is the low density of the material and the fact that prior to heating it occupies a much lesser volume than after heating. In addition, the material has a tendency to be statically electrically charged such that the particles will have some cohesion one for the other and will not easily flow into small spaces. Also, in manufacturing bodies -from such expandable plastic beads, which bodies are of intricate shape or have thin vertical sections, it is necessary to prefoam the material to partially increase its size. I That is, prefoaming or'preexpansion is a controlled partial expansion of the expandable beads. Such prefoaming must 'be carried out in yorder to assure complete expansion of the material and to obtain uniform densities and cohesion between the various beads. The prefoaming operationcauses the beads to be expanded to a size at which the above mentioned diliculties are magnified. Thus, such beads can be utilized to manufacture a structure having a discrete closed cellular wall which is impervious to moisture, if the beads can be uniformly distributed throughout a mold and heat applied thereto.

Accordingly, it is an Aobject of the present invention to provide an improved apparatus for forming finished articles from fused expandable plastic beads.

I It is another object of the present invention to provide, such an apparatus wherein the plastic beadscan be autov-rnatrcally and uniformly fed to the'cavity in the closed condition of the cavity.

-Yet another object of the present invention is to provide such a molding apparatus in which both the internal and external walls of the apparatus are uniformly heated to provide a uniform fusion and expansion of the beads positioned therein. v

It is a still further object of the present invention to provide such a molding apparatus which is entirely automatic in operation.

. A still further object of the Vpresent invention is to provide such a molding apparatus with ejectionY means integral therewith for quickly and efficiently removing the I finished article from the mold.

It is yet another object of the present invention to prov1de such a molding apparatus by means of which a measured quantity of such beads are fed to the mold apparatus to insure uniform filling of the cavity prior of description, however, the manufacture of cups is utilized',V

'as an example of the utility of the present invention.

Among the various characteristics of the material which produce manufacturing problemsl is thefact that theA ma-i to expansion and fusion thereof.

Yet another object.l of the present invention is to provide such an apparatus which lls the mold cavity with a measured amount of such expandable plastic beads and automatically removes from the vicinity ofthe mold any excess materials in order to prevent the unwanted expansion and fusion of such materials. y

It is a still further object of the present invention to provide such a mold apparatus which is simple and economical in use and which can beutilized overrepeated molding operations and for continuous length of time.

It is yet another object of the presentinvention to provide such an automatic molding apparatus which has a short cycle of operation for maximum production of such structures in any given length of time.

' It is another object of the present invention to pro-v vide an automatic molding apparatus which canbe oriented in the position most feasible for product ionpurposes. y

Yet aprimary object of the present invention is to provide an automatic molding apparatus for` forming objects of' expandable ,plasticl beads lwherein a vvacuum A 1s provided in the mold cavity to' supply .an increased pressure differential between the gas contained in thebeads of the molds ofuapluralmold machine; i FIGURE 3 is a detailed view of the ejectionv means of -themoldshown inFIGURE 2; f

presentinvention;` r

' FEGURE V8 is a detaiied View lin perspective illustratV pregnated in the" beads will deteriorate in storage, in

. prior artjapparatus'it has been necessary to:disca`rd the beads at a certain age thereof. The' present invention allows` the useof suchbeads by,ineifect, supplement-v ing Vther'ir'iteinal Vpressure "created in the beads by r.heating and molding the beads in'a vacuum.

, It is another objectfof the present invention to V.pro-

videfa vvmeans for molding vcups and similar articles as described having a non-planarbottom surfaces. The' novel Yfeatures'which arebelieved to/be vcharaczation fand method of operatiom'together with further Referringnow particularly to FlGURl-27 one of the molds constructed in accordance with the present invention Yis -shown in detail and inciudesin ygeneral amale portion and a femalerportion which areseparable along teristic of the presentinvention-both as toA its organi` objects andfadvantag'es thereofgwill be better understood? from the foilowingdescriptionconsidered in connection with the accompanying drawing in which a presently preferred embodiment of the invention isfillustrated by way of example.vv It is `tobe expresslyiunderst'ood,however,"

that the drawing is for/'ther purpose of; illustration. and

description only and isfnotrinten'dved as ka definition of thev limits. of the.v invention.

ln the drawing: j Y Y FIGURE 1 is a schermaticvow diagram iliustrating the operationl of the present invention;

f FiGURE 2 isa detailed view in section showing .one

Y nrooanszi, sand 6 Show in@ 'mais in accordance' .Y

` .with FIGURE 2 at various stages of the moldingoperation; i .y Y 1 Y YFIGURE' 7 shows' an illustrative cup utilized through out the present application asan `exemplary Vuse ofthe; f

ing the'iilling opening of the Ymold YPGURE 2; *Y

FiGURE'Q'is a schematic ow diagram of theflow conduits to and from :the mold which 'carry the plastic Y a parting line P--in-EIGUREZ. The male portion is.

designated generally as A'while the female portion is designated generally .asYBi InYFIGUREZ .theY1ongitu--" dnal Yaxis 2@ is shown'extending` throughout the length ofthe 'moldfandwill' be referredto hereinafteras a reference point to'fdescribe theorie'ntation of the various Vparts of the mold. lThnS, as shownfin FIGURE 2, the mold'isseparable at the parting line P by movingtho male portion of .the mold andthey female'portion ofthe mold relative to one'anotherr along the longitudinal axis 26.. The parting, line P will extend from the, exteriorv wall 22j'ofkthegmold inward transversely/"to thelongi-z tudinal axis lZtl of the cavity 25.215 described hereinafter. The cayity'i'is Ydefined by jthefinternalY wallfYZf of the Y female mold element `and .the externabwallflf ofthe male mold element,f which walls are "substantially-'parallel and spacedY apart bythe wall thickness desiredinthe nishedrstrructure.. `Y -Y f Acupeshaped structure is shownjin connection with the mold `of FIGURE 2 and is, shown as atinished article 46. in `FIGURE 6 `of the drawings. t'yfill be .noted `thatthe cup has an upper' flanged edge 41. which is connected by .truste-conical fside' 'wall 42am ka substantially transverse bottom sur-facek 43". The wallKV thickness Ms :substantially uniform throughout the structure., The Vside wallshavea slight draft of Vfive degtfees,for example, Vtof-,facilitatere-` 'moval of the 'article from the mold. It should `b e noted Y inthis connection that the finished vcup has ia discontinuity 'in the slope of the side wall as indicated at ddofFIGURE .6. lThe functionofth-is discontinuity will become more apparent'hereinafterrin connection with'the description of voperation fof the mold;y Thewall thickness ofthe structure Y being formed in the' illustrative Veinlbodiment lislof the order beads to and fromVthe-m'old'in accordance with the"`p`res ent invention; Y

FEGURE lOfis a Y element of themold apparatus;

FiGURE'll is a Yview in perspectivecorresponding toFiGURElQ of the male mold element; e

'4 FIGURE 12'is a partially schematic viewof arn'alter-y native means for feeding the plastic beads to thecayity `showing the apparatus/in the input' condition; 'Y l FIGURE V13 isfa View corresponding m etonne 12" showingvthe'apparatusin' the "closed position 'at4 which excess beads are exhausted; and. i Y

YFIGURE 14 is a sectional View of an `alternative .cup andejection means. v Y Y V,As discussed hereinabove, the expandable plastic beads asy obtained from the manufacturer are 'designated as expanded iniaccordancewithstandard molding procedures fof 060 tto .090. inch. The male portion Si? ofthe Vrholdis for-med of material which lhas a highly polished surface VA27 and vwhic'h'hasla highYheat conductivity for Yth`e` quicl transference of lheat through` themold rwall. The male mold. element `Stiy extends ifnorn atransverse shoulder Stato' a ,transverse bottom ysunface .51?, :with the, -sjideiwall ofthe k'moldgporrtion being: :of truste-conical Yconfiguration.Y

Thus, :thejrnold 'element Sti has; `aiiiinged-f upper` surface ywhich is transverseto thelongitudinal center 'linc ofthe,

`mold and which extendsoutwardiy from :thefc'enter line 12d.

to a .radiusatrSSs in the. figure ywhich isgreaterf than the maximum radiusofthe mold cavity*Themoldelernentii y `isconnected vto the mold housingeleinentV-Sti atth'e' badial,

vline 55 and is formed with a'igasftight seal 57 suppiiedby lan 0-ringV in a suitablev O-jring groove. The moldele'rnent .159 then extends toward 'the 'first yend tiwo'f the mold by raw beadsand can be purchased varioussiies.; n thepresent use Yof. this vinvention suchbeads are pref..

heretofore known to the-art toa .diameter` atYwhich they o vwill ll the mold uniformly in the proper quantity .for

a finished wall, as more' fully described hereinafter'. ."lny .Y

. the prefoamed condition if .the plastic beads-'are'con tainedwithin a closed volumesuch as a cup-shaped cavity.

andsubjected to heat thebeads will further expand under such temperature and will cause an internal pressure to becreated. VDuring the final-expansion ofthejbeadsithey togetherl tolform a liquid-impervious wall.

ffele'ment 'Ztiwwithan exterior-wall :7l1havingaico I i tionsimilar tothe coniignlragtiron of therinterna wallj59 isf-.the melampld ,element E@ lbut spaedftherefromzbyfa Y;

means .of `a frusto-conicalV shaped 'side'.wall-Sfwhich.is f integral with the bottom surfaceSZ.v Thus, the'male .por-ik tionof Ithe, mold is'also ofal cupeshaped configuration a closed bottom surface. )The-mold element Stia'isjroined to'theurnoldbody and more particularly totl'iemalepon" tion 5o thereof. :That is,` the mold sectionifttisj'formedasa separate unit 'with 'respect to the mold'zlbody S in .orderVV to providenecessary cavitiesifor the transmission ofheat- 4ing iiuid'to'the internal wall 590i the mold punition Sti.

Whenrassembled the moldportiont becomes an integral portionv .of the' mold bodyV 56 and denes therewith the mold surface 27 togetherwitlr Vfluid passagesin the ,form

of an annulus 60, .which annulusis connected by Various. .passages :such as 6d, 62, 63,64 androS toa iuid flow con-Y duit .do which in turni-sin 'communion 'on ,then-exterior surfaceof'the mold body and which; threaded-in order Y .to 'banned' a nuid, inlet l bed more'particllflarlyhereinafter; Y .Thus the body portionSfofV-the mold deiin distance sufficient to allow the passage of fluid through the annular cavity of) defined therebetween. That is, the male body portion A56 of the mold assembly is a transversely extending housing .with a male element extending inwardly and into the male portion 5u of the mold but spaced therefrom by a distance sufficient 'to form an annular .cavity du adapted to receive fluid through ports 6l through 65 from the fluid flow path A6, As lshown in FIGURES \2, 10 and l1, `the mold elements Sil and lil@ which define the mold-ing cavity Z5 are formed of metal, such as aluminum which has a high rate of heat conductivity. Conversely, it is .preferable :to form the mold body portions 56 and Ill@ of a heat insulating material such as epoxy resin. `As will .become more apparent hereinafter in connection with 'the` description of operation of the apparatus and the method of :the present invention, it is necessary to raise and lower the temperature within the mold cavity quickly during the manufacturing cycle, and it is accordingly necessary to avoid the creation of heat sinks in those portions of the mold apparatus where a temperature change is not necessary.

` a fluid outlet passage 75 Iwhich is in turn .connected-to a fluid outlet line at the female @fitting 76. The. annulus 74 is separated from the recesso@ `by the annular ring 77 `partion of mold element `Sli which contains radial fluid .passages 7S therethrough. In addition, the male body portion 'S6 defines a plurality of air inlet passages Sil extending from the outer end 51 of the mold inward and through the Wall of the male mold .to :a position proximate the break 82 in the slope :of the Wall. That is, as shown particularly in FIGURE 2, an annular ring 85 is positioned upon `the outer sunface -27 of `the male mold yand has a slope on the external surface 86 thereof which is coextensive with the slope of the male wall 88. A shoulder E@ is formed at rb'oth the annular ring 3S and the male wall in order toaccomrnodate insertion of the annular ring S5. An annular groove 92 is formed in lthe exterior -wall at the inner end ofthe annular ring 8d and extending slightly therebeyond such `that an annular opening is defined -between the outer end 93 of the ring 85 and the continuing surface 94 of the sloping male wall. Thus, the outer surface is discontinuous at this point and defines the discontinuity 46 in the cup. This ring 85 then provides a means for forming an annular opening in communication with the 'air passages du, which opening is small `in sizeY but extends circumferentially about the male mold and lis in communication with the `air passages flf.A Thus, as described more fully hereinafter, air injected through the opening Sil and through the opening 82 will for-m anejection stream of air for removing fthe finished structtue lfrom the male mold when it adheres thereto. By blowing between the cup and male mold, the cup is expanded slightly for easy rcl moval of the cup from the male mold.

Thus, referring particularly to FIGURES 2 and ll, the male'mold element comprisesa frusto-conical side wall 53 with a bottom wall .52 defining the interiorA bottom surface of the mold cavity at the surface 52. vThe interior wall surface of the mold cavity Z7 and thevb'ottom surface 52 thereof are to theleft of the parting line, P in FIGURE'Z, whereas the radially extending flange 55 having an 0-ring groove therein at the radialv surface l.'35,

Vwhere it isV ink abutting'relationship with the mold body 55, is to the right of the parting line P. Extending longitudinally frornthe flange 55 is thev annular ring 5l which defines a plurality of fluid ports 78 that connect the fluid cavity s@ with the annuiaf'auideuuet '74. The fluid outlet 74 is in communication with the fluid outlet passage 75. It should be noted that for optimum fluid circulation the fluid inlet line 66 extends from the upper portion of the mold body radially inward into communication with the longitudinally extending fluid inlet pasage 65. The passage 65 is then connected to the annular cavi-ty 6u which is in direct communication with the interior wall of the male mold element to cross the .entire surface thereof. Thus, fluid enters through the inlet 66 and passes through the various radial ports 6l, 62, 63, 64 and 65 to the 'fluid cavity du in contact with the walls 53 and 52 of the mold. The fluid then circulates through the fluid ports 78 and into the annular outlet fluid passage 74 to the fluidoutlet 75 positioned oppositelyvfrom the uid inlet 66. The annular fiuid outlet 74 increases in longitudinal width toward the fluid outlet 75 such that its cross-sectional area is considerably greater as it appreaches the fluid outlet '75. Thus, as shown in FIGURE 2, the annulus has a width extending longitudinally from the point 74a to 74b `at the uppermost position of the annulus and increases :to a considerably greater width extending from the point 74C to 74d at the lowermost portion of the annulus. Thus, as more radial ports 78 con' tribute their flow to the outward flow of fluid, the crosssectional area of the annular passage increases to accommodate such increased flow.

At this point it should be noted in connection with the presently preferred embodiment as shown in FIGURE 2 that the vend surface y52 of the male mold element 5l)y is not planar and does not follow a smooth curve but conversely circular indentations 52a lare provided vwhich in transverse cross-section give the surface 52 a double concave configuration emanating from the center axis of the bottom wall 52. That is, an indentation is provided in the surface 52 which is symmetrical about the longitudinal yaxis through the apparatus and which curves radially from the axis by describing a concavity extending from the highA point at the axis as shown in FIGURE 2. As will become more apparent hereinafter, this surface provides a means forv causing the plastic beads which irn` pinge upon the surface 52 to .be dispersed radially and in effect imparts the necessary flow to the beads causing the beads :to be spread radially outward from-the axis rather than piling upat this point.

Referring now to FGURES 2 and 10, a female mold element lill) of the mold apparatus is similar in configuration to the male element but is spaced therefrom such f that the inner wall 26 of the side Wall 106 defines the exterior Wall of the mold cavity 25.'y vThe female mold is continuous in configuration and symmetrical about the longitudinal center line 20 of the apparatus with a flanged upper end MP2 Ito the left, or female side, of the parting line P and a closed bottom wall M3 defining the bottom surface of the mold cavity 25. The flanged upper end 102 has a radius approximately equal to the radius ofthe flange 55 of the male element and is disposed adjacent the male flange 55 when the female and male portions "of the molding apparatus `are in mating engagement. A sealing ring groove 107 is provided in the circumferential surface of the flange 102 tol form a sealing engagement with the mold body 110. The bottom wall 103 of the female mold elementris approximately equal in thickness to the side wall 106 but is formed integral with an annular lip 103 which extends longitudinally to the left ofthe bottom wall in FIGURE 2 to define a t radially extending fluid groovey 109. That is, the bottom wall of the female mold element is, in effect, extensive in length to vdefine la radial outwardly convergentv which is the openingvthrough which kthe Vplastic beads are fed to the mold cavity 25 as defined hereinafter. Y

VA series of transversely extendingcircumferential baf-` es 112 are formed upon the outer surface of the side wall 106 of the 'female mold element to deiine fluid circulating paths114. That is,` in the presently preferred embodiment a series of equally spaced-apart circumferential baffles 112 are formed upon the outer surface of the Wall 106 and are of substantially equal height. In the embodiment'shown eight such baflies are used. Thus,` the female mold element-il is aiiixed Within'the female body portion 110 of the molding apparatus which is that inbefore, the mold body portionsV are `separable atthe- Y Vthe mated male56 and female' I1li@-bodyportions ofV the.

portion tothe leftk of the parting line P.' The mold body 111@ is again formed of a material which is resistant to heat transfer such as epoxy resin.' The mold body 110 defines a mateablevfrusto-'conical opening defined by the Wall 116vwhich conforms to the conguration ofthe eX- terior wall Vof the female mold element but is spaced there- [from to define the Huid iiow cavitiesf114 between the exterior surface 106" of the side walls 10o and the wall i of the `mold body 116. vThe Wall V116 is spaced from'this surfacelll-by an amount approximately equal to the height ofthe baffles 112. Thus, whenv the female mold' elementlltl is positioned Vin the mold body 110 the baffles 112 are in circumferential contact withthe in-KY teriorrwall of the cavity Vdeiined by the mold body, with` which the mold element Nilis mateable. The baflies in contact with the wall 116' therefore describe a plurality of annular fluid paths extending"circumferentially about Y' lthe-side Wall 106 of the mold element between the sideV wall and the mold! body. In addition to the'plurality of A,circumferential iiuid' paths 114 defined between .the'bafvfles '112 the iiuid groove V1199 provides an additional fluid path which passes overthe outer surface of the endwall 103. A iiuid inlet conduit 117 is providedfrom the upper surface ofthe mold body 110 and is threaded for the' connection of al uid inlet line. As shown particularly cavity and reduces thearnbient fairpressure therein'withw-V in FIGURE I'Zand schematically in FIGURE l0, the iiuid t v inlet conduitll'i is expanded longitudinally atthe upper- -inlet portion ofthe uidrrp'assagesin order to` span the g pluralityof annular passagesldand distribute fluid to Y each. Thus, atl the upperportion of the mold body the fluid inlet-passage' 117 is in efectfan-shaped andisrin uid communication with the iiuid groove 169 and each of the l'l'uid-y annular passages 114.' Similarly, a uid outletconduit 113' is provided -at thelower portion of theV mold body and is threadedfor connection" to a fluid outlet line'.v LLike the inlet pasage 111, the iiuidk outlet passage 11S is expanded longitudinally to providefliud `cornmunitzation with thel fluid groove 109 and'each ofthe 'fluid annular passages, 114. Thus, iiuidpassing into the mold body 110 will iiow throughfthe longitudinally eX- pandedl portions 117 of the fluid inlet `andinto each of K the annulus passages 114 whereit. will progress'by-gravity iriiow down oppositey sides ofthe side wall Moin Contact with the* surface 1%" and 1vvill pass fromreachfofthe passages. into the Viiuid outletV passagef118.

The female mold 'elementfltiil -is atiixed vto l.the :mold

body 11? by suitable means suchlas a mounting ring V120v which is'positioned within the mold body witha liangef parting lineP and a sealing ring fi'is provided at the parting -line between the body. portions Sound lit), to provideea fluid sealbetween the mated portions. The

` body :portion of the mold apparatus also deines =at the l parting line'avacuuman'nulus 131V which isin cornrnuni-v cationwith the cavity 25 at the parting line P.' That is,v

yas shown particularly in FIG-URE 2,Q, an annular-shaped cavity which in transverse cross-section is convergent toward the' upper end ofthe mold cavityk 25 istdened by mold apparatus.` Thel annulus ll'tl'i'sy of substantial width and narrows down to adecreased `area 132 extending between the flanges 55 and 192 ofthe male mold element and female mold element respectivelyfr At the radially'innerL mostpoint of the vacuum annulus .131"asrnallcircumferential passage 135 is provided to allow-the' passage of air from the mold cavity ZSto the vacuum annulus 131. The Width of the air passage135 when the'moldfiapparatus fis in-the mated condition is such-that it istoosmall to allow the passage of theplastic beads therethrough. Thus,

if a vacuum is created-in the vacuumfannulus 131 it will f extract air from the mold 'cavity'ZSs-but will not admit ofthe passage of theiplastic beads from the moldwcavity to the vacuum annulus., A-vacuum inlet conduit 136 is provided through the body. portion ofthe mold apparatus into communication with the'vacuum annulus 131.

Thus, as `shownin. FIGURE 2, inthe femalebody,portionY 110.21 conduitwhichis threadably iitted for connection toan air line is Adeiined which is inY communication with y the lva'cuunrann'ulus 1311 When the vmold bodiesA are Ymated the'v'acuum annulus 131 is a closedpa'nnulus in communication with the moldcavity 25.Y When aivac-V Y uum pump is connected to therair line (not shown) which is threadablyconnectedto thegair conduit 136the vac#` uurn4 drawn'in the annulus ll31y extracts air from the mold t out allowing vthe escape of the plastic beadstherefrorn.

'Inthe.female-body'portion 110, of the mold I apparatus tl.ie`re is provided a reciprocating plungerlttlwhich is reciprocally mounted along :the longitudinal centerline of 'the -moldy apparatus.y f The plungenMi includes a transversely extending-flange, which defines a piston 141 Ypositionedwithin the' cavity 142. `denedin the mold body.Y

The AcavityfJJZr is thus a 'cylinder which is substantially longerathan the thickness 'of the iangein order toA allow longitudinal movement ofthe iiange or pistont142 there- 1n. conta'ctwith the cylindricalwall of thecylinderfM'Zand is sealed with respecttheretoqby means of anuQ-ring ,143.V Y

An,V airy inlet port 144 is provided throughthe 'mold r body Yextendingfrom theexterior thereof to a position at the forward, or right side v,of the cylinder ,142 in FIG- URE 2 .such Ythat air: under pressure admitted'through the passageliwillexert a force upon thepistonin the direction; .toward the moldtcavityif Similarly/,fthe ksecond yairinlet port 145 isprovided throughthe rnold body inV communication with the: cylinder M2 at the position' to.

i therightof the piston in FIGURE 2 such thatjair orfluid` eirtending ,radiallyV` inward frnateable withV .therl annular lipjltl.; y r I v Thusyas shown particularly in FGUREXZ, thfnioldV apparatus comprises in 'general a male'mold portion-56' with the male-mold element-Sii afliXed-.tlieretoland aifei male element rnoldbody portionliilj with` thefemalernold` Y element'y 199 aiixed thereto. The male and female por-.yl 1 Vtions arefprovidedwith fluid inlet :conduits which distribute the fluid-,fromthereXterior source through cavities'whichl are in contactwith the walls'of the mold elementydening thernold cavity 25.-Y Means `are provided circulating vthe r fluidtoprovider even ilow over therequired surfacesafter l, VYwhich thejriiuidisV discharged from "therrnold 'apparait/us Y through theuid outlets "75 andxll. "As, discussedliterie-V .through the end Wall of thelfernalevzrnold ,element '-195.1 The plunger lttl isin generalran elongatecylinderfwith the'piston1li2 extendingiradially therefrom."v The 'plunger'.` 1f'iil-"islongitudinally movable Within the cylindery 151 formed vin the'rnold bodyf symmetrically Aaboutfithe"longi- 'Y 1 tudinalf center line thereof. flier-reasons ,which willl-be' t @discussed hereinafttr,*tthejpiungery ifi-il -preferablytisf The outer diameter'of thepiston 141 is in slidingA formed partially of plastic and partially of metal for heat conduction at the inner end of the plunger only.

ln its presently preferred form the plunger includes a plastic sleeve 152 which has an outside diameter substantially equal tothe inside diameter of the cylinder 151 and is in sliding contact therewith. The sleeve 152 is formed of plastic as is the piston 142. Positioned within the plastic sleeve is anelongate aluminum cylinder having an outside diameter approximately equal to the inside diameter of the plastic sleeve 152. The tubular plunger sleeve 154 is of substantially greater length than the plastic sleeve and piston portion of 152 and is aliixed thereto such that the ends 152 and 15d are substantially coincident. The plunger cylinder 154 is however of considerably greater length thanthe length of the sleeve 152 such that the sleeve defines a transversely extending shoulder 156 at the forward end thereof which is well within the cylinder 151. On the other hand, the tubular plunger 154 extends forwardly of the shoulder 156 to the inner end 150 of the plunger assembly. At its inner end 150 the plunger is closed. The cylinder within which the plunger is longitudinally movable is reduced in diameter proximate the inner end 157 thereof to provide a cylindrical portion 157 having an inside diameter substantially equal to the outside diameter of the plunger 154 which is in sliding contact therewith. An O-ring or similar sealing means 160 is provided between the outside diameter of the plunger 154 and the inside diameter 157 of the reduced cylindrical portion. The cylinder 151 of larger diameter is connected to the cylinder 157 of lesser diameter by a convergent wall 15S which is spaced substantially to the right of the shoulder 156. Thus, an annular cavity 163 is dened between the mold body and the plunger 15d which extends longitudinally from the shoulder 156 to thecylinder 157. The longitudinal extentof the cylinder 157 is such that it is greater in length than the longitudinal travel of the plunger assembly 140.

Suitable bearing and sealing means 165 are provided at the interior wall of the mold body in sliding bearing coilact with the sleeve 152 ofthe plunger assembly to allow continuous sliding movement of the plunger within the cylinder without undue wear and to Yprovide a seal between the mold body and the cylinder 142. The plunger 154 is tubular with the inner end 151i being closed but with an open rearwardend 166. Positioned within the tubular opening of the' plunger is a liuid conduit 167 Y which is aixed to the mold body by means of a threaded plug 168. The tubular conduit 167 is stationary with respect to the plunger assembly and extends inwardly into the plunger to a position at which its inner end 169 is` proximate the inner end 151B of the plunger 154 but spaced therefrom by a distance sufficient that the plunger in the retracted position as shown in FIGURE 2 will not be in contact with the inner end 169 of the tubular con# duit 167. A fluid path 170 is vprovided through the connecting means 168 with suitable'ttings for atiixing a uid line'thereto. The innerlend 1522154 of the plunger and sleeve is spaced fromtt'he fitting 168 by a distance which is suihcient at 'the retracted position ofthe plunger to provide a iiuid ow annulus 171 which is in communicavtion with a fluid outlet port 172. The iiuid outlet port is again provided with a threaded "fitting 173 to which l a iiuid outlet line can be connected. Thus, a tiuid liow path is provided such that iiuid is admitted through the fitting 168 along the fluid path 170 and thus through the length of the tubular conduit 167 and from the inner end 165 thereof tothe annular space 176 defined between j the tubular conduit 167 and the inner wall 178 of the It should be noted at this point that the plunger assembly, including the plunger 154- and the sleeve 152, is longitudinally movable from an extended position at which' 154 and the interior wall of the cylinder 151 is a sealed and closed cavity. At the extended position, however, the sealing means 160 is removed from thecylinder 157 such that an air passage exists from the cavity'163 through the cylinder 157 and to the exterior of the cylinder. Accordingly, an air path exists from the cavity 163 Vto the plastic feeding cavity 1S@ as described hereinafter. An air path 181 is delined through the mold body 115 from the exterior thereof at the threaded tting 132 in communication with the annular cavity 163 surrounding the plunger proximate the inner end thereof v between the shoulder 156 and the reduced diameter 157 of the cylinder. Thus, air can be injected into the cavity 163 and outward therefrom at the inner end of the cylinder through the space defined by the inner diameter 157 of the cylinder and the outer wall of the plunger Y when the sealing means 161i is extended from the cylinder 157.

Referring n-ow particularly to FIGURES 2 and 7, the plastic feeding path 18th is shown. Thus, an opening is defined through the mold body which extends from the exterior thereof radially inward. This opening 191i is provided with threads 191l for the connection of a conduit thereto. The opening 1% then progresses into la configuration as shown in FIGURE 7 which is a frustoconical opening of decreasing thickness which is in cornmum'cation at the inner end 191 thereof with the opening 104 through the end wall 153 of the female cavity 186. More particularly,r the opening 19t) into the mold body is spaced to the left in FlGURE 2'from the lopening 15dinto the mold cavity 25. The fwallsof the truste-conical plasticy iiow path are divergent -to the left in the figure .Y `from the opening 164 and are in communication with the opening from the exterior of the body. ln the clockwise direction as shown in FIGURE 7 from the opening 191i the thickness of the truste-conical annular space decreases. Thus, plastic beads admitted through the openkm5319311 will flow, under the force created by air pressure and the vacuum as described hereinafter, in a clockwise direction and also to the right and into the opening 1134iwhen the plunger is in the retracted position as shown in FIGURE 2. The annular frusto-conical plastic feedingvoid has its greatest diameter proximate the inlet 19t) and decreases in thickness as the plastic is dispersed toward the'opening 1643. `Further details of the mold apparatus will become more apparent in connection with the description vof the operation of the apparatus and the `rnethodof the present invention. However, it can be seen y that if the plastic beads in their pre-expanded condition are suppliedjto the flow path19tl when the plunger assembly 14% is in the retracted position as shown in PEG- 2, the plastic beads will be conducted into the mold cavity 25 under the inluence of the vacuum created in the vacuum annulus 131.` The beads will flow through the annular opening 131i and through the opening 146 in they end wallof the female mold element 106. `When the plunger is moved to thexextended position at which. it ycloses the opening 104 to malte a continuous end surface of the mold cavity 25, an air path exists between 'the air cavity 163 and the annular plastic flow cavity 15%.

When a stream of air is admitted through the passage 181 into the cavity 163, it then progresses outwardly past the plunger and intor the plastic lfeed path 181i to blow any beads remaining therein from the path i8@ and out of theY proximity of the mold which is to Vbe heated.

Referring now particularly to FlGURES l and 2, as has been previously discussed, When the mold cavity 25 is closed with the predetermined quantity of expandable plastic. beads containedl therein, and the beads are subjected to. an increase in vtemperature to the temperature' at which they expandV and fuse, the beads will fuse into position in FIGURE 2 prior to `or during the admission of the plastic beads ythrough the path 18h, lthe opening 'lbaud into kthe cavity 275. After the required quantity maintained-in the vacuum annulus-lrl andV thus in they :mold cavity 25 such that the ambient pressure surroundingthe expandable lbeads is considerably mospheric. Y n t t Hot Water in a pressurized system is usedas the heating means for raising the temperature ofthe-beads, after which. the mold iscooledto allow extractionfof the` V'molded cup in this embodiment again by means of cool-- ant Water circulated .through the fluid passagessurrounding the cavity. Accordingly, as shown in FIGURES l and 2, vhot Water is supplied from a hot .waterV portion of suitable apparatusto be used in Vconnection With -the'mold apparatus previously described, which hot Water isconducted to each of the iluidinlets of the mold. apparatus designated generally as Ml in FlrrUREV 1 and shown in detail and describedfin connection with PGURE l2.

less than at- Y a unicellular mass having a configuration yof the mold f cavity. v rlfhe molding apparatus is shown in the closedy 10v a coldjwatercirculating pump-,2297 .which pumps theV cooled water to the cold water inlety line. 21W vthroug'rrthe valve 2l@ when thevalve'ZltB is opened at the proper time in the operating cycle.V A by-pass line 228 `is provided `vvvitha bypassvalve 229 for short-circuiting the cooling water when necessary. Boththe hotwater system and the cold Water system are,maintainedsin a pressurized condition by means of the compression tanks224 for the cold .water system and V234i for` the lhot Water system. TheseA tanks are of the type Well'knovvn to the art which are pressurized by air pressure` conducted to the tamis throughthe airline 235. -Y i Similarly, in the hot Water system. hot water is conductedfrom the mold Vapparatus through the fluid outlets 75,- l and 173 into'the hotuwater., outlet line 263 and through `vthe' valve 294Mo thev hot Water return line :237. Thehot Water return line 237 passes tothe hot` Water boiler, wherefits temperature'is raised bypassing through the n, hot water boiler 240. The hot Water outletV line @di leadsfrom the boiler to the hot Water compression tank 234 and thence from the .tank throughia hot Water ci-rculatingpump 242 through the. hot Water. inlet line 290 the fluid inlets 65, l0? and 76 throughthe yhot Water inlet linebil'at atemperature of approximately 310 Similarly, a cold watersystem isconnectedto each-of the fluid inlets in .order that both hot and cold water can be circulated selectively through the system to raise or lower the temperature `ot the mold cavity25 at the *proper point in the cycle of'operation of :the apparatus.

Thus, referring particularly to FIGURE l, alhot Water fluid inlet line Ztl@ is connected to eachmofthe .tluid inlet I ports 66,;.117 and I tl. l.'the-hot WaterV is'connectedto l .I eachof these ports through suitable fittings and is V valved by a control valve Zul fotthe type which can beelectrically cycledby means of an electrical cycle timer 262/ connected therewith.. A hotiwater outlet line 263 is Vconnected to each of theV iluid outlet ports 75, 113 and 17.?, at the appropriate iittin'gsrin thebody of the mold apparatusi rthis hot Water outlet linefis also connected through au electrically operated valve 2:94. Similarlyracold Water vline Ztl? isk connected tofeach of theuid inlets 66, il?

and SiF/'t of the mold apparatus and a cold Water outlet linefZtlS is connected to each of the duid outlets '75, lill,

4 and 173-. VThe, cold Water lines are also valved by V.valves El@ andZlZ which are, connected to the electric'cycle timer 2%.

pump therein and through `an inlet lineextending from'Y thecooling tower to the heat exchanger designated asfZZZ., The waterfsystem is. closed such that Water pasingfrom the mold apparatus'Mk through the cold Water outletvline Zilli Whent'ne valveiV is Vopened will pass to theheat ex,-

chang'er 22S where its temperature-is loweredto approximately 126? Vror cooling purposesV in the moldV apparatus.l The cooled Lwater -ispassed from the 'heat exchanger:

Vthrough the cold Water line 223 and intoa 'compressionKL v tank 224 which maintains the'coldwaterV under pressure yto create a pressurized Waterv system. From the compression tanli'ZZfi the cold Waterinletfline 22e/:passes throughv and at a pressure of l0() pounds per square inch, Means are provided as shown in FIGURE 1 to utilize steam from the preexpansion section of the, apparatus. as a source of steam for makeup water in the watery system. It

should be noted alsothat heat at the pre-expansion stage is utilized to raise'the temperatureof the Vrbeads fed to the mold by conduit 272 in .'FlGUlUE ,9. Pre-heating ot' the beadsfnecessitates less of Vatemperature rise of the beadslin the mold. Y

, ln addition tothe. hotand ,cold-Water circulatingA systems, as has been previously described,V air lines are necessary for conducting airfunde'r' pressure into:the airV inlet-ports ll, i131 and Si) of the mold apparatus.

These lines'are connected respectively to the' :air .inlet ports 14.4%,.145, Si and Sil throughsuitable ,valvii'tggv The air linesare then connectedto asource of pressurizedair.

.mately l0 microns'of Hg iin; the.v presentlyV .preferred embodiment. In addition a conduit suitable for transV mitting the Yplastic beads fromY a ,pre-expander,Y which is of the type Well Vlinovvnfto theai't and not shown fin connection with the present yinvention','z to thepplastic inle yline 1% and intothe plastic feeding annulus i859.'

f- Thus vreferring tov FIGUREfSythe plastic conduit 2?@ ViscOnneet-ed at therthreads @tot the moldapparatus and extendsfrom a `plastic .beadrnanlfold ythrough a plastic inlet l'line `272fthrough a oneawayffilapper valve; 273. which permits the passage ot' the plastic beads from. the hopper in which. theyare stored yinthe pre-expanded' e Y condition,Y and thence fromthe Hap-per valve tojthe plastic .inletrrconduitt andinto theplastic feeding ,annulus 156. A Yreturn line visprovided betvveen the manifold 271 andthe plastic conduit 27d which allows the 'return [of plasticbeads .which .have entered the jannulus 13@ and been vremoved therefrom as excess material.. Thus', beads stgwhich permitsV their return Vto lthemanifold and their circulationi'baclr'through therme-expansion hopper. f. This isdone since the plastic beadswill acquire an electrostatic charge dueto :friction andmovernent. Due to such rcharge they `,have a -tendencyffto adhere audjto prevent t blown from the annulu's lill) by air admitted through'. Y theair inlet port-ljlrivlien the-plungerisat the extended position' at which it closes the Yopening lltlare blown. from'the line 27@ Vand upv/ard throughtaone-Way valve' Referring now to FIGURES 1 and 8, and FIGURES I 4, 5 and 6, the operation of the apparatus of the present invention and the method of the present invention can be described in connection with the presently preferred embodiment of the apparatus as shown and described hereinabove for forming a thin-Walled cup. The cup is of the configuration shown in FIGURE 7 with a recessed or concave bottom and smooth frusto-conical side Walls with a lip 41 at the upper edge of the cup as shown in the figure. Referring particularly to FIGURES 2 and 4, the mold apparatus M is mated by bringing the female portion and male portions thereof into engagement by means of operating mechanisms such as the operating rod 73 which can be reciprocated by a hydraulic piston or other means well known to the art. In FIGURE 2 the molding apparatus is shown in its mated position at which it defines the closed cavity 25 into which the pre-expanded plastic beads are to be injected. Thus, the two body portions of the mold are mated at the parting line P and are furtherurged into the mated position by reason of the vacuum created externallyvof the mold. At this load position as shown in FIGURE 4f the plunger assembly 140 is in the retracted position which is obtained by admitting air through the valve 255 to the air line or path 145 which subjects the inner side of the piston 145 to air pressure, to in turn force the piston toward the left in FIGURE 2 and maintain the plunger assembly at the retracted position. In this position the plastic feed-ing annulus 180 is in communication with the opening 104 through the end wall 103 of the female mold element. The mold cavity 25`is fully closed except for the opening 104. The vacuum pump 262 is creating a vacuum through the line 261 into the vacuum annulus 131. The vacuum in the annulus extracts air from the mold cavity 25 through the small circular opening '135. As described in connection with FIGURE 8, the plastic beads are drawn'froxn the mani-fold 271 which leads from the pre-expansion hopper to provide beads at the one-way check valve 273. With the plunger retracted and the vacuum annulus 131 creat-ing a vacuum in the mold cavity 25, the beads are drawn into the plastic feeding annulus 186 and thence through the open-ing 104 through the end wall of the female mold element d. As the plastic beads pass through the opening 164 they strike the double concave sur-face 52a in the end wall surface 52 causing them to be dispersed radially into lthe bottom portion of the mold cavity and to progress uniformly vlongitudinally through the mold cavity untily they reach the lip 41 of the cavity at the inner end thereof between the flanges 102 and 55 of the male and female mold elements respectively. After the proper quantity of pre-expanded plastic beads have passed into the mold cavity 25 to iill the mold cavity the air pressure in the cylinder 142 is reversed in direction by admitting air under pressure through the valve 254 into the air passage 144 at the left side of the piston 141 and opening the valve 255 to the atmosphere to let the air under pressure force the plunger assembly 140 to the right in FIGUR-E 2, as shown in FIGURE 5. At this position the plunger assembly closes the mold cavity by causing the inner end 150 of the .plunger to close the opening 104 as shown in FIGURE 5. Any plastic beads remaining within the plastic feeding annulus 189 are then blown therefrom by admitting air through the air passage 181 by means of the valve 257 in the air line 252. The beads blown from the annulus and thus from the passage 1% are blown outward through the plastic conduit 270 and through the one-way check valve 274 back to the manifold 271 from whence they are returned to the hopper.

The molding apparatus is then in the loaded position at wh-ich the mold cavity 25 is fully closed with the proper amount of expandable plastic material therein. The vacuum is continued in the vacuum annulus 131 such tha-t the air pressurewithin the mold cavity 25 is substantially less than atmospheric. Hot water is then admitted by means of the electric cycle timer which operates the hot water -valve 101 and admits hot water through the inlet line 200 from whence it passes into the molding apparatus at the hot water inlet conduits 6o, 107 and 170. Upon passing into the hot water inlet conduit 66 the water progresses through the orifices 61, 62, 63, 64 and 65 and into the hot Water annulus 6i) at the inner wall of the male mold element, thus heating the male mold element to the required temperature. Simultaneously the hot water passing inward through the hot Water inlet conduit 167 is spread longitudinally and passes into the groove 109 into each of the annulus fluid iiow paths 114 such that it progresses circumferentially around the exterior Wall of the female mold element to heat the mold el-ement tov the required temperature, At the same time the hot water passes into the fluid conduit 167 through the inlet 17d and to the inner end 1541 of the plunger to heat the end of the plunger to the required temperature. Thus, with the plungerin the extended or closed position at which it forms the remainder of the closed surface `of the mold cavity, all of the mold cavity defining surfaces'which are formed of aluminum are heated to t-he required temperature by the hot water. The hot water is left in the mold apparatus for the time required to heat the expandable plastic beads to the required temperature'l v It should be noted at this time that the body portion of the molding apparatus yare formedl of a non-heatconducting materal such as epoxy resin. All of the heat is concentrated at the mold element surfaces such that the material within the cavity 25 can be heated quickly `from a temperature which is considerably cooler than the required expansion and fusion temperature of the plastic material. In the presently preferred embodiment With the Water at a temperature of approximately 310 under a pressure of 100 p.s.i. the cycle time required to heat the material contained within the mold cavity to the required temperature is approximately five seconds. After the plastic material has expanded and fused, i.e., after a time interval of approximately five seconds, the Cycle timer opens the valve 2&4 to discharge the hot Water Within the molding apparatus and at the same time opens the valve 210 to admit cooling water to the molding apparatus in the same ow path as previously described,

at which it surrounds the mold element to reduce the temperature of the mold cavity 25. Again in the presently preferred embodiment a cooling time of approximatelyv five seconds is required. During the heating and cooling portions of the operating cycle the apparatus remains as shown in FIGURE 5 with the mold cavity closed but with the vacuum operating 'in the vacuum annulus 131 such that the cavity is constantly subjected to the decreased ambient pressure. At the end of the cooling cycle the plastic material will have fused and formed the cup as shown in FIGURE 7. The vacuum in the annulus and cavity is then released, after which the mold apparatus is opened by retracting the male portion from the female portion by means of the operating rod 73. When the male portion is retracted, the cup will be retained thereon due to the radial indentations in the exterior surface of the wall of the male mold element, which al-low the plasticy material to be formed therein in order that the male mold element will carry themolded objectl with it when the mold is separated. Accordingly, when the mold has been separated, air is admitted through the air line 253 by means of the valve 258 and beads.

into the air path 84B which projects the'air into the small annular groove S2. Air passingV outward from the groove flows between the male' mold wall and the inner l wall of the cup to force the cupfrom the male lmold,

element and thus to eject it from the Vmolding apparatus. At this point the mold-ing cycle has been completed. and

the apparatus is readyfor another production cycle. The

total cycle time in connection withthe presently preferred embodiment of the apparatus has been found to be approximately twelve seconds.

f `An alternative embodiment of the-parts of the apparatus defining the ejection air` path isshown in FIGURE 14. In this embodiment the ejection air annulus 82' is adapted to a cup configuration having'a smooth side Wall with no discontinuity or shoulder such as 45' in the presently preferred embodiment. Accordingly, fthe ,ejec

tion air annulus is positioned at the upper' lip .of the cupV in communication with the air passage Si) to again blow air between the cup and male mold to remove the cup therefrom.V l v Referring now to` FIGURES i12 and i3 there isshown partially schematically Van `alternative embodiment of the being in communication with said plastic inlet openingY at said-first'. position of said plunger, said plunger at'said second position thereof closing said inlet opening; means for moving said plunger selectively from said first to ,said second positiornmeans for selectively extracting air "from said cavity through said vacuum passage when said plunger ism said first position to :thereby create a pressure in said cavity substantially less than atmospheric to draw said beads from rsaid plastic inlet passage vinto said cavity; means forselectively heating said plunger proximate said inlet opening; means for exhausting air through said inlet passage at said second position of said. plunger Y to'exhaust beads therefrom back to saidv bead admitting apparatus for feeding the plastic beads to the mold cavity in the required quantity; In the alternativeembodiment aV gravityviiow of plastic beads to the opening 1M,- of the mold, cavity is utilized :to supplement the vacuum force causingthe beads y.to be drawn into the cavity.l t

Thus, as shown in FIGURE Vl2, the plastic beads;

enter Vthe Vmold apparatus and flow downward to the plunger 306 through Ian'upwardly extending'inlet port 301.

When the plunger is ingthe retracted or loadiposition the, t inlet port isiopen and inV communication with the openf ing it-i. After the proper quantity of LVbeads have been drawn into the mold cavity, the plunger is moved forward i to the closed position and the piston 362 closesl the inlet portAV and opens adownward extending outlet port 303. Excess beads then travel downward through theioutlet port and from the mold apparatus. Any beads remaining are blownl from the vicinity `ofthe plunger by a stream of air admitted throughY the airlinlet port 3%" as previously described. Y

`Thus, thelpresent invention provides an improvedep. Y

paratus for molding articles fromj expandableV plastic By means of theV present invention uniform moldingI conditions are achieved and the beads'rare exincrease the. pressure 'differential` between n the interior panded Vand fused under reduced .pressure in order to anrliexterior of the individual beads. The beads are fedl automatically and uniformly to lthe moidicavity inthe closed condition of the mold and the apparatus is particularly adapted to fully automatic operation.

What is claimed is:`

f l. apparatus for forming a thin-walled article of I'manufacture -by' the `expansion and fusion of expandable Vfusible plastic-beads comprising: a mold apparatus hous-v ing, Vsaid housing being longitudinally separable `along a v V"transverse parting line and including a male moldhousi ing and a female .mold housing-said male and female mold housing being formed'of insuiating material; a male mold element carriediby said male housing and a-female mold element carried by said .female nioldhousingysaid p male and' female mold elements being mateable at vthe matedV position of said male and female .housing Vto provide a mold cavity defining by the interior walls4 thereof the Vcontiguration of the article lto bemolded; a vacuum air passage defined by said` mated lmale and'fernale mold y elements Vin communication with said cavity proximate one endk thereof; a-plastlc inlet opening to said cavity ing extending axially into said cavity, said openinghavin'g a cross-sectional configuration substantially less than the Y crossesectional configuration of said second end-'ofl said moldV cavity., said female housing defining a'plasticvinlet Apassage therethrough in eoninluucationV with said-plasi -at thesecondA end thereof opposite said oneend, said f female mold element dening said opening, said open-1 means; a first fluid passage defined by said female mold housing' surrounding said femalel mold elementra second fluid passage dened `by said male-mold housing surrounding the interior Wall ofV said male moldV element;

means for selectively conducting heated fluid to said passages to raise the temperature within saideavity to a ternperatureab'ove the expansion andfnsion temperature of said beads;,means for selectively yconducting cooling fluid to said passages to lower thetemperature within said cavity to a temperature below the expansion and fusion'tempera4 ture of saidv beads; and means for'separating said mold 2. An apparatusy for formingia thin-walled'plastic cup by the expansion andfusionl of expandable fusible'plastic beads comprising: a mold apparatus housing, saidvhousing being longitudinally separable along `a transverse parting line and including-a ymalern'old housing `and a female mold housing, said Vmale and female mold housing being formed to insulating lmateriaha male moldfelementrcar-r ried by said malehousing and a female mold element. f carried :by said female mold housing,- saidV male and yfemale mold elementszbeing mateable at the mated positionvof said ymale and female housings to provide a mold cavity defining `by the interior walls thereof the `conguratio'n'ofthe cup to be molded, Vsaid molded cavity having longitudinally extending frusto-conical side walls and a transverse end wall; Va vacuum -air passageL defined by said mated maleand femaie mold velements'in commu knication with saidV cavity proximate one endA thereof;

a plasticV inlet opening to Vsaid cavity at the second endy thereof opposite ysaid lone end through ysaid'ei'id wall of said cavity, said femalemold elementdening said'opening, v said opening extending axiallyy into said cavity,

said opening'having a cross-sectional conigurationsubstantially less than the cross-sectional configuration of said transverse end wall vof saidy mold cavity, said female housing defining a plastic inlet passage-therethrough in communication' with lsaid plastic opening; means for `adkmitting saidplastic beads into said plastic inlet passage; `a longitudinally reciprocalV plunger `mounted insaid female-housing and movable from a first to -afsecond position, said plastic inlet passagebein'g in communication `with said plastic inlet opening at said iirstiposition of-said plungen--saidi-plunger lat said 'second position thereof closing said vinlet opening; meansV for moving said'plunger selectively fromsaid iirstgto'said second position; means for selectively extracting air from said cavity through said 'Vacuumrpassage whensaid plunger is in said first position Y to` thereby create@ pressure in said cavity substantially less thanjatmosphericzto `draw lbeads-from said plastic inlet'passage into said cavity; means forV` seiectively heating said plunger proximate said ,inlet opening; means i for exhausting `air through said inlet passage at said second position of said plungerto exhaust beads VtherefromV back to saidbead admittinglmeans; aiirst fluidl passage defined by said femaie mold housing surrounding said te nale mold'element;,a second-duid passage Vdefinedby housing to remove the molded article from saidappara-V tus. i Y' said male mold housing surrounding the interior Wall of said male mold element; means for selectively conducting heated iluid to said passages to raise the temperature Within said cavity to a temperature above the expansion and fusion temperature of said beads; means for selectively conducting cooling fluid to said passages to lower the temperature within said cavity to a temperature below the expansion and fusion temperatureof said beads; and means for separating said mold housing to remove the molded article from said apparatus.

References Cited in the tile of this patent UNITED STATES PATENTS Carter Ian. 19, 1943 Darrnore Aug. 24, 1954 Stastny et al. May 8, 1956 Kelly Dec. 11, 1956 Harrison et al Nov.- 18, 1958 Harrison et a1. Sept. 6, 196() 

1.AN APPARATUS FOR FORMING A THIN-WALLED ARTICLE OF MANUFACTURE BY THE EXPANSION AND FUSION OF EXPANDABLE FUSIBLE PLASTIC BEADS COMPRISING: A MOLD APPARATUS HOUSING SAID HOUSING BEING LONGITUDINALLY SEPARABLE ALONG A TRANVERSE PARTING LINE AND INCLUDING A MALE MOLD HOUSING AND A FEMALE MOLD HOUSING, SAID MALE AND FEMALE MOLD HOUSING BEING FORMED OF INSULATING MATERIAL; A MALE MOLD ELEMENT CARRIED BY SAID MALE HOUSING AND A FEMALE MOLD ELEMENT CARRIED BY SAID FEMALE MOLD HOUSING, SAID MALE AND FEMALE MOLD ELEMENTS BEING MATEABLE AT THE MATED POSITION OF SAID MALE AND FEMALE HOUSING TO PROVIDE A MOLD CAVITY DEFINING BY THE INTERIOR WALLS THEREOF THE CONFIGURATION OF THE ARTICLE TO BE MOLDED; A VACUUM AIR PASSAGE DEFINED BY SAID MATED MALE AND FEMALE MOLD ELEMENTS IN COMMUNICATION WITH SAID CAVITY PROXIMATE ONE END THEREOF; A PLASTIC INLET OPENING TO SAID CAVITY AT THE SECOND END THEREOF OPPOSITE SAID ONE END, SAID FEMALE MOLD ELEMENT DEFINING SAID OPENING, SAID OPENING EXTENDING AXIALLY INTO SAID CAVITY, SAID OPENING HAVING A CROSS-SECTIONAL CONFIGURATION SUBSTANTIALLY LESS THAN THE CROSS-SECTIONAL CONFIGURATION OF SAID SECOND END OF SAID MOLD CAVITY, SAID FEMALE HOUSING DEFINING A PLASTIC INLET PASSAGE THERETHROUGH IN COMMUNICATION WITH SAID PLASTIC OPENING; MEANS FOR ADMITTING SAID PLASTIC BEADS INTO SAID PLASTIC INLET PASSAGE; A LONGITUDINALLY RECIPROCAL PLUNGER MOUNTED IN SAID FEMALE HOUSING AND MOVABLE FROM A FIRST TO A SECOND POSITION, SAID PLASTIC INLET OPENING AT SAID FIRST POSITION OF SAID PLUNGER, SAID PLUNGER AT SAID SECOND POSITION THEREOF CLOSING SAID INLET OPENING; MEANS FOR MOVING SAID PLUNGER SELECTIVELY FROM SAID FIRST TO SAID SECOND POSITION; MEANS FOR SELECTIVELY EXTRACTING AIR FROM SAID CAVITY THROUGH SAID VACUUM PASSAGE WHEN SAID PLUNGER IS IN SAID FIRST POSITION TO THEREBY CREATE A PRESSURE IN SAID CAVITY SUBSTANTIALLY LESS THAN ATMOSPHERIC TO DRAW SAID BEADS FROM SAID PLASTIC INLET PASSAGE INTO SAID CAVITY; MEANS FOR SELECTIVELY HEATING SAID PLUNGER PROXIMATE SAID INLET OPENING; MEANS FOR EXHAUSTING AIR THROUGH SAID INLET PASSAGE AT SAID SECOND POSITION OF SAID PLUNGER TO EXHAUST BEADS THEREFROM BACK TO SAID BEAD ADMITTING MEANS; A FIRST FLUID PASSAGE DEFINED BY SAID FEMALE MOLD HOUSING SURROUNDED SAID FEMALE MOLD ELEMENT; A SECOND FLUID PASSAGE DEFINED BY SAID MALE MOLD HOUSING SURROUNDING THE INTERIOR WALL OF SAID MALE MOLD ELEMENT; MEANS FOR SELECTIVELY CONDUCTING HEATED FLUID TO SAID PASSAGES TO RAISE THE TEMPERATURE WITHIN SAID CAVITY TO A TENPERATURE ABOVE THE EXPANSION AND FUSION TEMPERATURE OF SAID BEADS; MEANS FOR SELECTIVELY CONDUCING COOLING FLUID TO SAID PASSAGES TO LOWER THE TEMPERATURE WITHIN SAID CAVITY TO A TEMPERATURE BELOW THE EXPANSION AND FUSION TEMPERATURE OF SAID BEADS; AND MEANS FOR SEPARATING SAID MOLD HOUSING TO REMOVE THE MOLDED ARTICLE FROM SAID APPARATUS. 